BS6 Thermal Management System

The development of a thermal management system for BS6-compliant trucks was a complex task. Alkraft faced several key challenges: Increased Thermal Performance in Constrained Space, Cost Constraints, and Extended Product Life. Alkraft introduced its 4th generation of folded tubes, along with a new fin geometry which played a central role in enhancing heat transfer efficiency while optimizing the system’s weight and durability. The new system featured a wider and more proportional design with less overhang and a core geometry with greater tube density. This not only improved thermal performance but also reduced the system’s mechanical and thermal shock susceptibility. A thorough re-evaluation of material selection led to the use of optimized materials that enhanced the system’s overall performance and durability. The radiator frame mounting was completely redesigned for better durability and vibration resistance. The tank was also redesigned with external ribs for extra stiffness to withstand pressure pulsation. The CAC (Charge Air Cooler) mounting brackets were redesigned on both the top and bottom sides with rubber bushings, significantly improving vibration dampening. The new core, featuring Alkraft’s proprietary 4th generation folded tubes and high-performance fin geometry, delivered exceptional thermal efficiency. The repositioned stay connection at the bottom side reduced overhang, leading to a more proportional design and improved weight distribution. The BS6 system featured sliding joints that provided allowance for expansions and contractions due to temperature variations. This helped prevent failures resulting from thermal fatigue. Remarkably, the new system had zero failures in the field, demonstrating its robustness and reliability. Moreover, the value engineering efforts led to a significant cost reduction, making the product more competitive in the market.